Professional Documents
Culture Documents
2008
www.mesa.org
Agenda
Introduction
Plant Floor Visibility
Trends and Observations
Improve
MES Products
Product Selection - best
practices
Conclusions
Supply Chain
Raw material
producer
Objective:
Objective:
Maximalisation
Maximalisationcustomer
customersatisfaction
satisfaction
and
andprofit
profitfor
forall
allpartners
partners
Transport
Supplier
Factory
Distributor
Factory
11
01
01
01
1
MA
TE
RI
IN
FO
R
MA
T
IO
N
FL
Retail
AL
F
OW
LO
W
Distributor
Retail
01
10
10
10
Consumer
Rapid changes,
complex environment
Regulatory requirements
General Food Law
Sarbanes-Oxley
Globalization
Branding
Make or buy?
Where to produce?
Raw Material
Supplier
Transport
Supplier
MA
TE
RI
AL
F
MA
TIO
N
Management of inventory
replenishment process
Distributor
LO
W
Retail
FL
OW
Distributor
Retail
NF
OR
Plant
Plant
11
01
01
01
1I
00
11
01
01
0
Consumer
Increased
Increased "agility"
"agility"
(product
(product availability)
availability)
Delivery
Delivery to
to schedule
schedule
Source:
Source: AMR
AMR Research
Research
Produce
Produce to
to schedule
schedule
ERP
MES
Agenda
Introduction
Plant Floor Visibility
Trends and Observations
Improve
MES Products
Product Selection - best
practices
Conclusions
Improve
Focus, make choices
Consistent strategy and execution
business processes
organisation & people
tools
Business
processes
Strategic assets:
production and supply chain(s)
Organization
People
Enterprise
objectives
Tools
incl. IT
SMART Objectives
Specific
What exactly are we going to do?
Measurable
How much are we going to do?
'This is the last strategy of our management !'
Acceptable
Is there support for what we want to do?
Realistic
Is it feasible what we want?
Timing
When will we be ready?
It is not a perfect strategy, but we apply it until we
know something better !'
64%
64%
Lean
Lean initiatieves
initiatieves
61%
61%
Drive
Drive standards
standards and
and consistency
consistency across
across
global
global manufacturing
manufacturing networks
networks
43%
43%
Optimize
Optimize performance
performance at
at
individual
individual plants
plants and
and factories
factories
43%
43%
Improve
Improve Sales
Sales && Operations
Operations
planning
planning process
process
0%
0%
Source:
Source: Aberdeen
Aberdeen Group
Group
32%
32%
10%
10%
20%
20%
30%
30%
40%
40%
50%
50%
60%
60%
70%
70%
46%
46%
Building
Building flexibility
flexibility into
into manufacturing
manufacturing
and
and supply
supply chain
chain processes
processes
43%
43%
Integrating
Integrating systems
systems into
into common
common
factory
floor
information
platform
factory floor information platform
36%
36%
Deploying
Deploying real-time
real-time information
information
to
to decision-makers
decision-makers
36%
36%
Consolidating
Consolidating the
the management
management and
and
reporting
of
manufacturing
information
reporting of manufacturing information
0%
0%
Source:
Source: Aberdeen
Aberdeen Group
Group
29%
29%
10%
10%
20%
20%
30%
30%
40%
40%
50%
50%
Internal IT Challenges
Gap
Gap between
between ERP
ERP and
and
factory
factory floor
floor
52%
52%
Incompatible
Incompatible and
and
inconsistent
systems
inconsistent systems
41%
41%
Lack
Lack of
of timely
timely
information
information to
to make
make
informed
informed decisions
decisions
37%
37%
Lack
Lack of
of strategy
strategy to
to unify
unify
information
across
information across
manufacturing
manufacturing
33%
33%
Lack
Lack of
of funds
funds and/or
and/or lack
lack
of
of perceived
perceived value
value
0%
0%
Source:
Source: MESA
MESA International
International
27%
27%
10%
10%
20%
20%
30%
30%
40%
40%
50%
50%
60%
60%
Processes
Organization
Applications
Data
Technical infrastructure
Production
Production
Maintenance
Maintenance
Quality
Quality
Inventory
Inventory
Latency
between business metrics and operations that caused them
100%
90%
80%
70%
Annually
60%
Quarterly
50%
Monthly
40%
Weekly
< 24 hours
30%
20%
10%
0%
Source:
Source: MESA
MESA International
International
Business Movers
Others
Example: Quality
10
10
Agenda
Introduction
Plant Floor Visibility
Trends and Observations
Improve
MES Products
Product Selection - best
practices
Conclusions
Participants 2008
2004
2006
2008
55%
42%
3%
47%
46%
9%
36%
51%
13%
48%
17%
35%
45%
18%
37%
40%
22%
38%
64%
65%
55%
Size (employees)
More than 150
Between 50 and 150
Less than 50
Established
Before 1990
Questionnaire
Vendor information
General
Improvements
Interfaces
MESA compliance
ANSI/ISA-95 compliance
Technical aspects
Mobile solutions
Mining
Mining
Building&&Infra
Infra
Building
Utilitiesand
andPublic
Public
Utilities
Sector
Sector
Oil&&Gas
Gas
Oil
Petrochemical
Petrochemical
Press&&Printing
Printing
Press
Home&&Pers.Care
Pers.Care
Home
BulkChemicals
Chemicals
Bulk
MedicalDevices
Devices
Medical
LifeSciences
Sciences
Life
Paper&&Pulp
Pulp
Paper
Cons.Packed
Cons.Packed
Goods
Goods
FineChemicals
Chemicals
Fine
HeavyMetals
Metals
Heavy
Aerospace&&
Aerospace
Defense
Defense
Plastics&&Rubber
Rubber
Plastics
Semiconductors
Semiconductors
Machinery&&Tool
Tool
Machinery
Pharmaceutical
Pharmaceutical
Food&&Bev.
Bev.
Food
Automotive
Automotive
Electronics
Electronics
70%
70%
60%
60%
50%
50%
40%
40%
30%
30%
20%
20%
10%
10%
0%
0%
ProficyPlant
PlantApps.
Apps.
Proficy
Wonderware
MES&EMI
Wonderware MES&EMI
aspenONE
aspenONE
PISystem
System
PI
Shopfloor-Online
Shopfloor-Online
Qubes
Qubes
Business FLEX
FLEX
Business
SIMATICIT
IT
SIMATIC
FlexNet
FlexNet
Quartis
Quartis
MWare
MWare
YokogawaMIPP
MIPP
Yokogawa
ADICOM
Suite
ADICOM Suite
Dabom-iVisualizer
Dabom-iVisualizer
FactoryTalk
FactoryTalk
Easy95
Easy95
GlobalSCREEN
GlobalSCREEN
HydraMES
MES
Hydra
iTACMES
MESSuite
Suite
iTAC
MESplus
MESplus
PMPMS
PMS
PM
PRODAC
PRODAC
Objective
Objective
XSSuite
Suite
XS
EmersonCS/AMS
CS/AMS
Emerson
Producim/Pharmacim
Producim/Pharmacim
InQuMES
MES
InQu
Mestec
MES
Mestec MES
R2E-MES
R2E-MES
UnisoftCELLS
CELLS
Unisoft
Camstar
Mnfg.
Camstar Mnfg.
nanoTrack
nanoTrack
SAP-VisipriseMnfg.
Mnfg.
SAP-Visiprise
AegisFusion
Fusion
Aegis
Ampla
Ampla
D2000Entis
Entis
D2000
PAS-X
PAS-X
PVSS
PVSS
HAI*QPM
HAI*QPM
MEScontrol.net
MEScontrol.net
nMetricSuite
Suite
nMetric
Pertinence
Suite
Pertinence Suite
PlantiT
iT
Plant
Proficy
Tracker
Proficy Tracker
Solumina
Solumina
SYPROS
SYPROS
ActiveAccurate
Accurate
Active
EyelitMES/QMS
MES/QMS
Eyelit
intraFACTORY
intraFACTORY
WIPtrac
WIPtrac
XFP
XFP
4P
MES
4P MES
BronerMES
MES
Broner
PSImetals
PSImetals
QMOS
QMOS
Operator
Operator
20
20
15
15
10
10
55
00
2002
2002
90%
90%
75%
75%
80%
80%
79%
79%
2005
2005
79%
79%
2008
2008
66%
66%
70%
70%
60%
60%
50%
50%
50%
50%
48%
48%
38%
38%
40%
40%
30%
30%
20%
20%
10%
10%
0%
0%
Continuous
Continuous
Process
Process
Batch
Batch// Semi
Semi
Process
Process
Discrete
Discrete
Make
Maketo
to Stock
Stock
Make
Maketo
to Order
Order
Engineer
Engineerto
to
Order
Order
Assemble
Assembleto
to
Order
Order
100%
100%
Helpdesk
Helpdesk++Support
Support
Helpdesk
Helpdeskonly
only
80%
80%
Support
Supportonly
only
None
None
60%
60%
40%
40%
20%
20%
0%
0%
N.
N.America
America
S.
S.America
America
Europe
Europe
M.
M.East
East && Africa
Africa Asia
AsiaPacific
Pacific
Performance
ormance
Perf
Analysis
Analysis
Product
Product
Tracking &&
Tracking
Genealogy
Genealogy
Maintenance
Maintenance
Management
Management
Process
Process
Management
Management
Quality
Quality
Management
Management
Labor
Labor
Management
Management
DataCollection
Collection//
Data
Acquisition
Acquisition
Document
Document
Control
Control
Dispatching
Dispatching
ProductionUnits
Units
Production
Operations //
Operations
Detail
Detail
Scheduling
Scheduling
Resource
Resource
Allocation&&
Allocation
Status
Status
66
80
80-- 100%
100%
55
60
60-- 80%
80%
44
40
40-- 60%
60%
33
20
20-- 40%
40%
22
00-- 20%
20%
11
2001
2001
2008
2008
ANSI/ISA-95 Functional
Model
Order
Order
Processing
Processing
(1.0)
(1.0)
Production
Production
Scheduling
Scheduling
(2.0)
(2.0)
Material
Materialand
and
Energy
EnergyControl
Control
(4.0)
(4.0)
INVENTORY
INVENTORY
OPERATIONS
OPERATIONS
MANAGEMENT
MANAGEMENT
Procurement
Procurement
(5.0)
(5.0)
Source: ANSI/ISA-95
PRODUCTION
PRODUCTION
OPERATIONS
OPERATIONS
MANAGEMENT
MANAGEMENT
Production
Production
Control
Control
(3.0)
(3.0)
MAINTENANCE
MAINTENANCE
OPERATIONS
OPERATIONS
MANAGEMENT
MANAGEMENT
Product
ProductCost
Cost
Accounting
Accounting
(8.0)
(8.0)
Product
Product
Shipping
ShippingAdmin
Admin
(9.0)
(9.0)
INVENTORY
INVENTORY
OPERATIONS
OPERATIONS
Product
MANAGEMENT
MANAGEMENTProduct
Inventory
Inventory
Control(7.0)
Control(7.0)
QUALITY
QUALITY
OPERATIONS
OPERATIONS
MANAGEMENT
MANAGEMENT
Quality
Quality
Assurance
Assurance
(6.0)
(6.0)
Maintenance
Maintenance
Management
Management
(10.0)
(10.0)
Research
Research
Development
Development
&&Engineering
Engineering
Marketing
Marketing
&&Sales
Sales
100%
100%
Production
Production
90%
90%
Maintenance
Maintenance
80%
80%
Quality
Quality
Inventory
Inventory
70%
70%
60%
60%
50%
50%
40%
40%
30%
30%
20%
20%
10%
10%
Analysis
Analysis
Tracking
Tracking
DataCollection
Collection
Data
Execution
Execution
Dispatching
Dispatching
Detailed
Detailed
Scheduling
Scheduling
Resource Mngt
Mngt
Resource
Definition
initionMngt
Mngt
Def
0%
0%
82%
82%
80%
80%
2007
2007
64%
64%
60%
60%
59%
59%
52%
52%
2008
2008
40%
40%
20%
20%
No
Nosupport
support
100%
100%
0%
0%
Production
Production
Maintenance
Maintenance
Quality
Quality
2006
2006
Inventory
Inventory
80%
80%
2007
2007
2008
2008
60%
60%
Consider Best-of-Breed
for Maintenance, Quality
and Inventory ?
33%
33%
33%
33%
40%
40%
24%
24%
20%
20%
10%
10%
0%
0%
Production
Production
Maintenance
Maintenance
Quality
Quality
Inventory
Inventory
0%
0%
Operations//Detail
Detail
Operations
Scheduling
Scheduling
ResourceAllocation
Allocation
Resource
&Status
Status
&
60%
60%
46%
46%
40%
40%
20%
20%
0%
0%
2004
2004
53%
53%
2005
2005
65%
65%
2006
2006
62%
62%
2007
2007
2008
2008
68%
68%
Expected
Expected
2009
2009
60%
40%
20%
53%
46%
0%
2004
2005
80%
2006
Performance
Performance
Analysis
Analysis
ProductTracking
Tracking&
&
Product
Genealogy
Genealogy
73%
73%
Maintenance
Maintenance
Management
Management
100%
100%
Process
Process
Management
Management
80%
80%
QualityManagement
Management
Quality
10%
10%
LaborManagement
Management
Labor
DataCollection
Collection//
Data
Acquisition
Acquisition
DocumentControl
Control
Document
20%
20%
Dispatching
Dispatching
ProductionUnits
Units
Production
100%
100%
90%
90%
80%
80%
70%
70%
2004
2004
2005
2005
2006
2006
2007
2007
2008
2008
Exp.2009
Exp.2009
60%
60%
50%
50%
40%
40%
30%
30%
100%
73%
2007
76%
78%
65%
2008* Exp.2009*
2003
2003
2004
2004
2005
2005
2006
2006
2007
2007
2008
2008
90%
90%
80%
80%
70%
70%
60%
60%
50%
50%
40%
40%
30%
30%
20%
20%
10%
10%
0%
0%
ISO
ISO or
or CMM
CMM
Own
Own Quality
Quality System
System ISO,
ISO, CMM
CMM or
or Own
Own
Certified
Certifiedor
or
Assessed
Assessed
Valid
ValidCertificate
Certificate
Regulatory
100%
100%
2002
2002
90%
90%
2005
2005
2008
2008
80%
80%
70%
70%
70%
70%
63%
63%
57%
57%
60%
60%
50%
50%
50%
50%
40%
40%
30%
30%
20%
20%
10%
10%
0%
0%
deployed
deployed FDA
FDA
developed
developed GAMP
GAMP
21
21 CFR
CFR Part
Part 11
11
Compliant
Compliant
Validation
ValidationDossier
Dossier
85%
85%
SOA
SOA
84%
84%
Web based
based
Web
architecture*
architecture*
Thin Client
Client
Thin
80%
80%
DNA
DNA
Distributed
Distributed
Architecture
Architecture
Load
Load
Balancing
Balancing
Client/Server
Client/Server
Architecture
100%
100%
85%
85%
80%
80%
62%
62%
67%
67%
60%
60%
40%
40%
22%
22%
20%
20%
0%
0%
2002
2002
2003
2003
2004
2004
2005
2005
2006
2006
2007
2007
2008
2008
Agenda
Introduction
Plant Floor Visibility
Trends and Observations
Improve
MES Products
Product Selection - best
practices
Conclusions
Staged Approach
Change Management
Awareness
Specification
&
Feasibility
Selection
Realization
Maintenance
&
Support
Im
pa
ct
Project Management
Time
Awareness
Specification
&
Feasibility
Selection
Selection process
Objectives: acceptance and active
participation of all involved
Convinced of:
Long List
Phase 1
Short List
Phase 2
Final Selection
Phases
1. Determine shortlist
2. Find the champion!
Determine shortlist
Organization
Focus
&
Scoping
Involvement
Management
"Process owners", key users
ICT department
Technical department,
engineering
Knock Out
&
Other Criteria
Organization
Small steering group
(Bigger) selection
group
Get Info
&
Evaluate
Short
Short
List
List
Organization
Focus
&
Scoping
Knock Out
&
Other Criteria
Get Info
&
Evaluate
Short
Short
List
List
Organization
Focus
&
Scoping
Knock Out
&
Other Criteria
Get Info
&
Evaluate
Availability of support
Suitability of MES product
Support by product of
relevant main functions
specific processes/activities
Preconfigured solutions
Regulatory compliance
Quality system vendor
Short
Short
List
List
Organization
Focus
&
Scoping
Knock Out
&
Other Criteria
Get Info
&
Evaluate
Short
Short
List
List
Prepare
Requirements
Document
Vendor
Meetings
Final
Evaluation:
Selection
MES
MES
Product
Product
Requirements document
Objectives for MES implementation
Business processes within scope
Required functionality
Interfaces with other systems
Few relevant (open) questions
Specific test case (small)
"Open" Questions
Prepare
Requirements
Document
Vendor
Meetings
Final
Evaluation:
Selection
MES
MES
Product
Product
Prepare
Requirements
Document
Vendor
Meetings
Technical:
sufficiently reliable
does it fit to company's strategy and policies
Financial
Cultural
Final
Evaluation:
Selection
MES
MES
Product
Product
Agenda
Introduction
Plant Floor Visibility
Trends and Observations
Improve
MES Products
Product Selection - best
practices
Conclusions
Closing remarks
"No idea!" - deadly answer?
Companies knowing their
shortcomings best, improve most!
Metrics matter!
Technology is enabler
It is all about people !